FINITE ELEMENT ANALYSIS OF A LOCALLY PRODUCED SPUR GEAR FOR WINDMILL WATER PUMPING SYSTEMS USING REVERSE ENGINEERING

This study focuses on the finite element analysis (FEA) of a spur gear locally manufactured for use in a windmill-powered water pumping system. The analysis was carried out under static loading conditions to understand how stress is distributed across the gear teeth, detect possible areas of deformation, and evaluate the overall safety factor. These factors are critical to ensuring that the gear operates reliably and has a long service life. The drive and driven gears were modeled and assembled using SolidWorks CAD software, based on carefully defined design parameters suited to the operating conditions of the system. Theoretical guidance was drawn from classical works by Dudley and Tuplin, whose research continues to shape modern gear design practices particularly in stress analysis, tooth geometry optimization, and fatigue resistance. Using ANSYS 15.0, the FEA results showed a maximum contact stress of 328.48 MPa, which is well below the allowable limit of 730.52 MPa, producing a safety factor of 2.224. This indicates that the gear is structurally safe and capable of withstanding the expected operational loads. The results are consistent with values obtained from analytical methods based on AGMA and ISO 6336 standards, as well as findings from previous studies such as Deshpande and Utpat (2014). The close correlation between the analytical and simulated outcomes validates the reliability of the modeling approach and confirms the suitability of the locally produced helical gear for windmill water pumping applications.